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7/27/2019 IPA June Issue 09
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P R O M O T I N G O N - S I T E P O W E R A N D C O G E N E R A T I O N
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JUNE 2009
Looking to Asia forsolutions
I N D E P E N D E N T P O W E R A S I A
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Invitation to Participate...
Neb Saric or Richard Teasdale at Global Media Publishing LimitedGlobal House, 13 Market Square, Horsham, West Sussex, RH12 1EU, UK
Tel: +44 (0) 1403 220750 Fax: +44 (0) 1403 220764
E-mail: [email protected]
Sales Agents:
For Further Details, please contact:
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CHP/GAS TURBINES 9Steve Dunlop outlines the temporary power and loadbank
services provides for the 323m-long FPSO Peng Lai, the largestoilfield ship ever built in China.
GEN-SETS 12
John Dorman reflects on a range of generators aimed the Asian
markets which have been designed to provide reliable powerin high ambient temperatures while also keeping down noise
and emissions.
STEAM TURBINES 13
The Makuhari New City's District Heating and Cooling Centre,by EnergyAdvance, relies on steam and Wärtsila engines with a
power generation efficiency of 45.6%.
BOILERS 14
Korea South East Power runs an eco-friendly power plant withthe latest DeSOx & DeNOx System - but a new fluidised bed
boiler is key to the operation.
SWITCHGEAR 16
The market for gas-insulated high-voltage switchgear has neverbeen more buoyant when you consider three recent contracts
involving India, Korea and China, reports IPA.
TURNKEY 17
IPA takes a look at the 565 MW Bugok II CCGT Power Plant inSouth Korea which has just been handed over by Siemens
Energy.
EMISSIONS 18
Singapore's power generation industry has made significantreductions in its carbon emission intensity. One of its reduction
leaders is Senoko Power.
Editor:
Aidan Turnbull
Sales Director:
Neb Saric
Publisher:
Richard Teasdale
Journal Assistant:Zoë Taylor
Accounts Division:
Sally Gasson
Far East Sales:
C H Park,
Far East Marketing Inc
German/Danish/Swedish Sales:
Mario Dobresko
Russia Sales:
Sergy Stanovkin
US Sales & Subscriptions:
Alex Carter
Asia-Pacific Correspondent:
John Goss
Contributors
Aggreko; Cummins; Wartsila; Doosan,Korea South East Power;
EnergyAdvance; AREVA; Siemens
Energy; Senoko Power; Daio Paper
Corporation; JFES; GE Energy; BWE;
Alstom.
Published by:
Global Media Publishing Ltd
Global House, 13 Market Square,
Horsham, West Sussex, RH12 1EU,
UK. Tel: +44 (0)1403 220750
Fax: +44 (0)1403 220751
Website: www.gmp.uk.com
© Worldwide Independent Power
(ISSN 1468-7100).
Subscription price £120 (UK),
£180 (overseas) per year.
Please send address changes to
Worldwide Independent Power,
Global House, 13 Market Square,
Horsham, RH12 1EU, UK.
Printed by Manor Creative, UK
Auditors: ABC applicationapproved October 2006
In the next issue• CHP/Cogeneration
• Diesel/Gas Engines
• Gas Turbines/Gears• Heat Exchangers
• Gen-Sets/Loadbanks
• Filtration/Test/Measurement
• Design/Software/Simulation
Power news from around the world 6
C O N T E N T S
R E G U L A R S
Our power portfolio includes:
Makuhari District Heating and Cooling Centre (MDHCC), Page 13.
J u n e 2 0 0 9
P R O M O T I N G O N - S I T E P O W E R A N D C O G E N E R A T I O N
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JUNE 2009
Looking to Asia forsolutions
I N D E P E N D E N T P O W E R A S I A
New
Technology
for Asia
The Peng Lai (above) is the largest floating, production, storage and offloading (FPSO) vessel ever built inChina. Key to the project was theinstallation of a power package from Aggreko. See page 9 for the story.
8-10 June - NEC - Birmingham
IP&EE2010Independent Power & Energy Europe
The 565 MW Bugok II CCGT PowerPlant in South Korea, Page 17.
GMP
Global Media Publishing Ltd
7/27/2019 IPA June Issue 09
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WORL DWIDE LOA DBA NK SPECIA L I S TS
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systems must be fully tested to make surethey’re up to the job - you need a stable,
continuous and variable power generation
test to imitate real loads, in real time. You
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No other company specialises in worldwide
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I S A L E S I R E N T A L I
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Why look anywhere else?
For more information, contact us on
(+44) 01283 531645
Or find us on the Internet at www.crestchic.co.uk
You can also email us: [email protected]
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W O R L D W I D E I N D E P E N D E N T P O W E R • J U N E 2 0 0 9
5
EDITOR’S LETTER
EUROPE ASIA-PACIFIC MIDDLE EAST
AFRICA AMERICAS
WELCOME
A warm welcome to this month’sissue of Worldwide Independent
Power - as always bringing youcloser to the stories and issuesaffecting on-site power andcogeneration around the world.For editorial comments, please donot hesitate to contact the editor.
BIENVENUESoyez le bienvenu à cette issue deWorldwide Independent Power.
Comme d'habitude, nous vousapportons toujours plus près dessujets qui affectent l'énergie et laco-generation sur place autour dumonde.N'hésitez pas contacter lerédacteur pour des commentaireséditoriaux.
WILLKOMMEN
Herzlich Willkommen zur Ausgabedieses Monates von Worldwide
Independent Power. Wie immerbringen wir Sie näher heran an dieEreignisse und Geschichten derStromerzeugungsindustrie rund umdie Welt.Für redaktionelle Kommentare undAnregungen wenden Sie sich bittean den Autor.
BIENVENIDO
Bienvenido a esta edición deWorldwide Independent Power.Como siempre, acercándolo a lostemas que afectan a la energía y a
la cogeneración in-situ. No dudeen contactar con nuestro editorpara cualquier cuestión editorial.
BENVENUTI
Benvenuti a questa nuova edizionedi Worldwide Independent Power.Come sempre cercheremo dioffrirvi storie e questioniriguardanti on-site power ecogeneration a livello globale. Percommenti editoriali, si prega dicontattare l'editore.
Is the cheap energy dream over?
Economic reports suggest that global energy consumption will increase by 44% between 2006
and 2030, driven by strong long-term economic growth in the developing nations of the world.This is the conclusion of a study from the ‘International Energy Outlook 2009"’(IEO2009)
released by the Energy Information Administration (EIA). While world energy demand in the near
term has slumped slightly as a result of the global economic downturn, most countries already
anticipate that energy consumption growth rates will return to pre-recession levels within a very
few years. China isn’t even waiting for this to happen - it appears to be forging ahead to meet
future demand by building at least one new power plant every week.
If you are into big numbers, here are some for you. Total world energy use is predicted to rise
from 472 quadrillion British thermal units (Btu) in 2006 to 552 quadrillion Btu in 2015 - and then to
678 quadrillion Btu in 2030. As a consequence of this the costs behind energy production have to
come down. What this means is that over the next few years as prices rise, it is the relatively
cheap, unconventional resources - such as extra-heavy oil, coal-to-liquids, and gas-to-liquids, oil
sands and biofuels such as rapeseed oil and fats derived from animals - which could be fuelling
more of the power stations of the future.
Certainly, from examples on the Continent, tallow made from rendered-down cow carcases
appears to be working out as a renewable and ‘green’ energy resource. See page 25 for our full
report on the Mouscron Biomass co-gen plant example in Belgium. Currently producing 18MW of
‘green energy’ - enough to meet the needs of 44,000 families and offer further profit from
recoverable ‘waste’ heat. Its operators suggest that a plant like this can reduce CO2 emissions by
66,000 tonnes a year. The EIA believes that world production of unconventional resources - which
totalled 3.1 million barrels per day in 2006 - will expand to an amazing 13.4 million barrels per day
in 2030 - which represents 13% of total world liquids supply in 2030.
EU Commissioner for Energy, Andris Piebalgs, believes that research and development into
alternative power generation systems along these lines is crucial and reflects the energy and
climate change policies set by the EU. Clearly, the EU has a sort of 20:20 vision.
By 2020 - Piebalgs says - the EU will seek to reduce energy usage across Europe by 20% while - atthe same time - boosting renewable energy to 20% of the EU’s overall final energy consumption.
Greenhouse gas emissions in Europe are also projected to be cut by 20%.
“Making energy systems more sustainable and secure is one of the greatest challenges for Europe.
The potential is definitely there. It is now essential to unlock it and find appropriate ways to work
for industry, research and government to work together to achieve our common targets,” he says.
This kind of approach would appear to be the way forward to achieving EU Energy and Climate
Change Policy objectives as well as reducing the costs involved with producing energy at affordable
prices. But will it actually happen by 2020? Watch this space.
Aidan Turnbull
Editor
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N E W S
6
Two team up for
contractsAREVA, teaming up withKorean contractor, DAELIMIndustrial Co., Ltd., hasbeen awarded a contractby Korea Hydro & NuclearPower Co., Ltd. (KHNP),South Korean nuclearpower plants operator toreplace the 6 steamgenerators on the Ulchin 1& 2 NPPs during outagesplanned for 2011 and2012. For the purposes ofthis project, a consortiumhas been set up, jointlyby AREVA and DAELIM.AREVA as Original
Equipment Manufacturerwill lead the consortiumand perform the primarysystem and licensingoperations in co-operationwith KHNP and KoreaPower Engineering Co.,Inc. (KOPEC). DAELIM willimplement all the second-ary and local activitiesassociated with thisproject.
Toshiba & TENEXThe Toshiba Corporationhas announced a memo-randum of understanding(MOU) on discussionstoward co-operation inthe nuclear fuel businesswith Joint Stock CompanyTechsnabexport (TENEX),a group company of JSCAtomenergoprom ofRussia, which supervisesRussia's civilian nuclearpower generationbusinesses. TENEX is saidto have long-standingexperience and expertisein providing uranium
enrichment services andproducts.
China contract for
Canadian SolarFounded in 2001,Canadian Solar Inc.(Canadian Solar) is avertically integratedmanufacturer of solarcell, solar module andcustom-designed solarapplication productsserving customers world-wide. Canadian Solar hasbeen chosen to supply
solar panels for 80,000rural households inSichuan province.
JFE Environmental Solutions has received its thirdcontract for an advanced biomass gasification plantbased on its updraft gasification technology. The
new plant is owned by Daio Paper Corporation and islocated at Daio's Kani-Works facility in Shikokuchuo-shi, Ehime-ken Prefecture, Japan.
The Daio gasification plant generates a syngasderived from wood for the existing production
facilities. The syngas replaces heavy oilconsumption and consequently reduces the site'sdependency on fossil fuel for paper production. Thisis a completely new application involving a gasifierin Japan, says DPC.
Peter Laursen, License & Partner Manager forBabcock & Wilcox Vølund A/S told IPA: "The VølundSystems™ biomass gasification facility was originallydeveloped as a power generation plant.
“This new application, with energy conversion,will be the model of an epoch-making solution thatwill help industries reduce green house gasemissions and energy costs,” he concludes.
Daio seeks biomass gasification approachIn brief...
Anniversary for GE Energy's Jenbacher
engines in Yamagata wood-to-gas plantGE Energy's Jenbacher gas engineshave completed their first year ofservice in a wood gas-to-energyplant in the Yamagata Prefectureof Japan. Two Jenbacher gasengines capable of generating2MW of electricity were installedat the plant in 2008 and are cur-rently being fuelled by gasifiedwood chips from a nearby forest.
The plant is seen as an importantspecialty gas-to-energy technologymodel which supports theJapanese government's initiativesto expand renewable energy pro-duction to help meet its emissionsreduction goals under the Kyoto
Protocol.The wood gas-fuelled power
plant was installed by Kanagawa-based JFE EnvironmentalSolutions. The plant is owned andoperated by Yamagata GreenPower, an electricity distributioncompany and subsidiary of renew-able energy development firmJapan Biomass DevelopmentCompany.
GE Energy said that a key designfeature of the plant is its woodgasification system. JFE has
licensed the updraft gasificationboiler technology from Babcock &Wilcox Volund of Denmark.
GE Energy noted that Asia's woodgas segment represents a newgrowth opportunity for itsJenbacher gas engine business,which has previously installed sim-ilar units in wood gas plants inEurope and North America. GEEnergy - a unit of General ElectricCo. (GE) - expects its Asia-Pacificbusiness to continue growing rap-idly this year, supported by gov-ernments' carbon reduction effortsand stimulus packages.
[Right]The 6021 from GE Energy.
Chiyoda licenses flue gas process to BWE
The Chiyoda Corporation, Japan's leading engineering and constructioncompany, has it has reached an agreement with Burmeister & WainEnergy (BWE) to license its CT-121flue gas desulphurisation processtechnology for use at Asnaes Power Station, which is owned by themajor European energy provider Dong Energy.
The Asnaes coal-fired power station in Kalundborg is Denmark'slargest generating facility, with total capacity of 1,057MW. Under theagreement, Chiyoda will license the CT-121 process to BWE, and BWEwill be responsible for engineering, procurement and construction Thisis the first contract acquired since Chiyoda executed a technologylicense agreement for Europe with major Danish energy provider BWEand Italian company Salvatore Trifone & Figli S.p.A., the parentcompany of BWE, in 2004. The CT-121 process already has a 22% share
of the US market, where environmental regulations are becomingincreasingly stringent.
I N D E P E N D E N T P O W E R A S I A • J U N E 2 0 0 9
Typical papermaking process at DPC.
7/27/2019 IPA June Issue 09
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Answers for energy.
Isn’t it amazing to have so much protectionfunctionality in such a compact device?
E 5 0 0 0 1 - U 3 1 0 - F 7 2
- V 1 - 7 6 0 0
With SIPROTEC Compact, Siemens as technology leaderoffers protection relays with a vast amount of functionality
in a compact housing.
• Easy to pre-wire and secure replacement of relays due to removable current and voltage terminal blocks.
• Set hardware configuration like binary pick up levels and CT taps through software settings.
• Future proofed through flexible an upgradable communication modules.
• SIPROTEC Compact inherits SIPROTEC 4 relay functionality – proven success with an installed base of
almost 1 000 000 units.
www.siemens.com/siprotec-compact
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8
N E W S
In brief...
India buys in
transformersThe Power Grid
Corporation of India hasordered two 500 MVA trans-formers from Areva T&DIndia. The 400 kV, three-phase units will be used toaugment capacities at 400kV substations atMalerkotla and Patiala inPunjab.
Kyrgyzstan opts for
hydro schemesKyrgyzstan intends to buildtwo hydropower plants,Kambarata 1 andKambarata 2, even though
Uzbekistan and Kazakhstanhave objected over sharedwater rights. Experts inKyrgyzstan claim that theplants will improve energyand water security in theregion.
Sri Lanka gets energy
development moneyThe Asian DevelopmentBank has approved loans ofUS$160m for the CleanEnergy AccessImprovement project in Sri
Lanka. The loans will beused to develop renewableenergy, energy efficiency,and increase access torural homes.
Geotherm plant
project begins in
Java2010 marks the inaugura-tion of a 30MW geothermalpower plant project atKaraha Bodas in Garut,West Java, costing in theregion of US$50m. The
plan is to complete it by2013.President Director PTPertamina GeothermalEnergy, Abadi Poernomotold IPA that Pertaminawas ready to fund theproject. "It will be fundedby a corporate loan, fromPertamina to its subsidiary,Pertamina GeothermalEnergy - PGE," Abadi said.The power plant will havea 30 megawatts capacity,but have the capacity forexpansion if needed.Thiswas originally a joint
project betweenPertamina, PLN and theUS-based Karaha Bodas.
OKI & HEH agree China dealIt's been just 16 weeks sinceHongkong Electric Holdings Ltd
bought the entire issued sharecapital (HK$5,680 million) ofOutram Limited from Cheung KongInfrastructure Holdings Ltd. (CKI).Outram is a company formed byCKI to hold 45% equity interests inthree joint ventures owning powerplants in mainland China.
Through Outram, HEH now holds45% equity interests in three powerplants, namely Zhuhai Power Plantin Zhuhai city, the neighbouringJinwan Power Plant and SipingCogen Power Plant in Jilin
Province.Group Managing Director of HEH,Tso Kai-sum, said this is anexcellent transaction for HEH,allowing HEH to take a strategicstake in the electricity generationbusiness in the mainland.
"We have been looking forsometime for an opportunity toinvest in the China power marketand this transaction will allow usto acquire very high qualitygenerating assets, most of whichare strategically located inGuangdong Province adjacent toHong Kong. I believe ourshareholders will find this
transaction highly-attractive whichshould be positive for our share
price," Mr. Tso added.The Zhuhai and Jinwan power
plants are strategically located inthe load centres in the westernpart of Pearl River Delta, anindustrial centre that is in need ofpower supply and with growthopportunities.They accounted forabout 7% of Guangdong Province'sthermal electricity output in2007.
The generating capacity of thethree power plants located atZhuhai, Jinwan and Siping are
1,400MW, 1,200MW and 200MWrespectively. Both Zhuhai andJinwan power plants are equippedwith flue gas desulphurisationplants, while Siping is currentlypartially equipped and in theprocess of full upgrade. With thistransaction, HEH will haveinterests in 8,457MW of totalgenerating capacity.
The Sihanoukville Special
Economic Zone (SEZ) in Cambodiais constructing a 90MW coal-firedpower plant which will enterservice in 2010 as part of thegovernment's 2013-18 CambodiaPower Development System plan.The proposed national grid will becontrolled by the state-runElectricite du Cambodge.Special Purpose Transmission
Licences will be available toprivate companies to operatesections of the grid, he said.It is expected that these willmostly be used to supply largeindividual consumers as well asrural areas off the main grid.
Electricity cost from18 US centsper kilowatt-hour in Cambodiacompared to only around 5.4cents per kilowatt in Vietnam.The high cost of electricity was
due to the country's almost total
reliance on fuel imports. Majorindustries and Special EconomicZones within 10 kilometres ofsubstations will be able to sourceelectricity on a direct feed.
This will give them acomparatively lower grid tariff byexempting them from networktransmission charges.
Phnom Penh, which accounts for85% of Cambodia's electricityconsumption, will be the centralpoint of the proposed grid.Substations will be built in thecapital, Kampong Speu, Takeo,Kampot and Sihanoukville by2011.
The grid will be connected towestern Cambodia by 2012 tosupply electricity to Siem Reap,Battambang and BanteayMeanchey.
Norwegian-operated SN Power
Invest is bidding for the Angathydropower plant in thePhilippines and for otherstate-contracted independentpower producers' capacities. Inthe Philippines SN Power hasalready entered into a jointventure with Aboitiz PowerCorporation to invest in thecountry's hydropower sector.
In 2006, the joint venturecompany SN Aboitiz Powerbought the 360 MW Magathydropower plant as part of
the government's privatisationprocess of the power sector.The Magat plant is the largesthydropower plant in thePhilippines. It draws waterfrom the Magat Dam andoperates as a peaking plantwhich sells energy through thederegulated electricitymarket. The dam is also amajor source for irrigation,serving approximately 85,000hectares of rice land. The damis owned by the irrigation
authorities who areresponsible for regulating thedam.
SNPI seeks Angat
hydropower plant
Cambodia’s coal-fired plantdestined for Sihanoukville
Alstom to provide wind farms for TokyoAlstom has been appointed byThe Tokyo Electric PowerCompany (TEPCO) as theexclusive supplier for the new
Higashi Izu wind farm inShizuoka Prefecture, Japan.This represents Alstom's firstcontract in the Japanese windpower market since acquiringEcotècnia in October 2007.This is Japan’s fifth wind farmusing Alstom's technology.Under the terms of thecontract, Alstom will supply,install and commission thewind farm's eleven Eco 74 windturbines.The wind farm will have a
total approximate electricaloutput of 18 MW and will becommissioned in October 2011.Alstom has customised itsdesign to conform to the strictJapanese Building StandardsLaw.
I N D E P E N D E N T P O W E R A S I A • J U N E 2 0 0 9
China’s Shandong wind farm.
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9
CHP & GAS TURBINES
T
he result of a multi-million pound
deal between ConocoPhilips China
Inc (COPC) and the China National
Offshore Oil Company (CNOOC), the one
thing which really impresses observers is
this vessel’s sheer size.
The Peng Lai FPSO is three times the
size of New York’s Statue of Liberty, piled
one top of the other.
It has an overall length of 323 metres, a
breadth of 63 metres and a depth of 33
meters. It has an onboard storage
capacity of 2 million barrels of crude oil.
The FPSO vessel's processing capability
amounts to 190,000 barrels of crude oil
per day with 510,000 barrels of fluids
coming from the wellhead platforms perday.
The sides and bottom of the vessel's hull
are double skinned with 24 ballast tanks
built into the double skin, with 17 oil
cargo tanks and two crude tanks taking up
the bulk of the volume.
What are FPSOs for?There are in fact two main types of
FPSO vessels in operation today; firstly
there is the converted oil tanker FPSO and
secondly there is the purpose built option.
The vessel's design type will depend on its
proposed area of operation.
These specialist vessels are particularly
effective in remote or deepwater
locations where long lengths of expensive
seabed pipelines are not cost effective or
practical. The FPSO eliminates the need
to lay these long distance pipelines from
the deep sea or remote oil well to an
offshore terminal. FPSOs can also be used
in smaller offshore oil fields which may be
exhausted in a few years and do not
justify the expense of installing a fixed
offshore oil platform and the pipelines.
With all of the sophisticated technologyand oil production equipment onboard -
plus the crew's living requirements - the
CHP & gas turbines in offshore oil
extraction
FPSO needs to have a reliable power plant
onboard to supply all of the vital energy
needed.These large purpose-built power plants
are the key to all of the FPSO's
operational functions and to its overall
success. The power plants are specifically
designed for the task ahead and carefully
installed during the build-up period in the
shipyard when the topsides of the vessel
are being completed.
Before the FPSO is moved to its location
the power plant, together with all of its
support and distribution systems, must be
thoroughly tested to ensure the reliability
of this key component.
The testing of the power system is
carried out by highly trained and
competent technicians using loadbanks
that will simulate the full load required
by the FPSO onto the power plant.
On this project the arduous testing wascarried out by Aggreko which has been
supplying temporary power and loadbank
services during the construction,
commissioning and critical periods on
FPSOs since 1998.
Not only has the company fully tested
many power plants and electrical systems
on FPSOs they have also supplied large
amounts of temporary power to specialist
offshore construction yards as the new
vessels are being built.
Additionally, in some cases Aggreko has
been asked to supply power to the FPSO
during the critical tow period when all of
the vessels electrical systems are tested
and then the power plant will be
.
The Peng Lai has the distinction of being the largest floating, production, storage and offloading (FPSO) vessel ever built in China. Key to the project was the installation of a
power package providing the commissioning power for the topside installation during the critical run-up and test phase, reports Steve Dunlop.
The Peng Lai FPSO relies on Aggreko power packages to run its systems.
I N D E P E N D E N T P O W E R A S I A • J U N E 2 0 0 9
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CHP & GAS TURBINES
commissioned when the FPSO is at its
location over the wellhead. Many records
were broken during the Peng Lai’s con-
sturction phase. In a unique cross-corpo-
ration deal in March 2005 ConocoPhilips
China Inc (COPC) and its partner, the
China National Offshore Oil Company
(CNOOC), awarded the contract to
Shanghai Waigaoqiao Shipbuilding (SWS), a
subsidiary of the China State Shipbuilding
Corporation (CSCC).
This company was tasked with the
construction and delivery of the FPSO
hull. At that time, the 281,000 DWD (Dead
Weight Tonne) Hai Yang Shi You 117 FPSO
vessel was to be the largest ever to be
constructed in China.
Topside integrationOnce the FPSO's hull had been construct-
ed in the SWS shipyard in China it was
towed down to the Sembewang Marine
Offshore Engineering (SMOE) shipyard in
Singapore for its topside integration to
commence prior to the commissioning
process. The FPSO's 20 specialist topside
modules were fabricated in Singapore;
they were designed to have an operating
weight of 40,000t, which is one of the
largest FPSO topsides in the industry.
When completed, the vessel consisted of
20 topside modules plus one flare tower
and seven pipe rack modules.
It took approximately 26 months to
construct and complete the enormous hull
in China prior to towing it down to the
SMOE specialist offshore construction
shipyard in Singapore where the modules
were built. The tow was made by two
new ocean-going tugs which at five knots
took 16 days to reach the SMOE yard.
Once commissioned, the newly named
Peng Lai FPSO was towed into the South
China Sea where it formed part of the
Phase II at the PL 19-3 oil field. This
phase also included the wellhead plat-
forms and a central processing facility.
ConocoPhillips Asia had previously
worked with Aggreko on the Belanak FPSO
project and based on that performance
awarded a contract to the power company
for a 4MW temporary power supply at avoltage of 3.3kVat 50Hz.
The power contract included supplying
the power package with a complete fire
and gas detection and suppression system,
a bulk fuel system, a fuel transfer pack-
age, earthing transformers, a control
room plus full operation and maintenance
services. As in the previous project, space
was limited on the deck of the FPSO
which meant a stacking system in which
the generators were placed on top of the
HV transformer, spares container, control
room and bulk fuel tank.
The functions of this temporary power
package were to provide the
commissioning power for the topsides
installation during the critical run-up and
test phase for the numerous electric
motors, this process included the 350HP
sea water booster injection pumps and
the slurry injection system which are
crucial once the FPSO is fully operational.
The many circuits and distributionboards were fully tested and energised to
ensure that once the FPSO's main power
plant was commissioned that these sys-
tems will work. Additionally, the FPSO's
lighting and auxiliary power circuits are
energised to supply temporary power for
lighting, HVAC and other essential services
onboard right up to the sail-away.
The second phase of the project for
Aggreko and one that comes close to the
final phase of the commissioning process
on the FPSO is the run-up and testing of
the onboard permanent power generation
system.The 56MW power plant for the FPSO
Peng Lai consisted of two 28MW, 35MVA
Nuovo Pignone Frame 5 gas turbines.
In order to fulfil and to satisfy all of the
testing parameters of the FPSO
classification society and after discussion
with ConocoPhillips, Aggreko was asked to
provide a Resistive Reactive loadbank
testing package equivalent to 45MW at
10.5V, 50Hz.
The space challengeA challenging feature of this particular
loadbank package for the Peng Lai FPSO
was that storage space for any equipment
on the quayside was extremely limited.
This severe lack of available space for the
package resulted in Aggreko being asked
to minimise the space required by
stacking the loadbank package.
This stacking process significantly
reduced the overall footprint of the spe-
cialist testing equipment thus enabling
the yard and ConocoPhillips to make best
use of the remaining space.
The testing of a main power generationpackage was crucial to the success of the
entire FPSO project. Without reliable
power supplies offshore the Peng Lai
vessel would be a lifeless ship and a very
expensive one at that.
Of vital importance was the fact that
the Aggreko testing package enabled the
ConocoPhillips commissioning team to
fully load test the two essential 28MW gas
turbines to ensure that they would indeed
load share and operate efficiently when
synchronised together.
The Peng Lai FPSO broke many records for size and capacity in its
construction.
www.aggreko.com
Internet linkInternet link
I N D E P E N D E N T P O W E R A S I A • J U N E 2 0 0 910
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FOLLOW THE LIGHT.......
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machines.
MarelliGenerators focuses on Synchronous
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Whenever you need power to rely on follow the light.
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12
GEN-SETS
Anew series of generators in the
range of 175 - 220kVA is currently
being launched on the Asian
market. Designed to work quietly andefficiently in tropical temperatures the
new generator models are powered by the
latest QSB7 engine which is said to offer
improved noise reduction as well as the
'best in class' in relation to performance,
due to its higher power density capability.
In high ambient temperature
environments the generator sets are
capable of providing in some cases up to
20% more power when compared with
previous models.
The generator sets also boasts advanced
SIIIA emission compliance almost two
years ahead of the scheduled regulatory
requirements which will come into force
for 2011-2017.
In addition, the compact format (all
thanks to the reduced size of the engine
and optimised arrangement) of the QSB7
series generators is destined to appeal to
applications where space is a key consid-
eration, says the manufacturer.
Further benefits include a new
PowerCommand® 3.3/motorised circuit
breaker option, ideal for sensitive envi-
ronments where synchronising with other
generators or the mains is required to
ensure an immediate seamless and
consistent flow of power (all units feature
PowerCommand 1.2 control as standard).
The compact design also encourages
improved access to the generator sets,
whilst the patented recessed 2-point
lifting feature on the enclosed application
provides a further ease of handling
advantage.
Commenting on the new range of eightQSB7 platform based generators John
Dorman, General Manager of Cummins
More power to your generators
John Dorman reflects on a range of generators aimed the Asian markets which have
been designed to provide reliable power in high ambient temperatures while also
keeping down noise and emissions.
Power Generation Middle East and Africa
told IPA: "This launch demonstrates our
commitment to leading the market in
relation to the development of
generators. These boast optimum
performance coupled with advantageous
convenience benefits, whilst also setting
the standard in terms of emissions and
low noise compliance.
He said: "The fact that the new QSB7
generators fulfil the EU NRMM (Nonroad
Mobile Machinery) Regulations emissions
requirements a whole two years ahead of
schedule provides a perfect example of
the company's continued support of this
important industry issue."
Features to look for in the new unit
include:
* Compact/robust design for the base
frame;
* Manual, automatic and paralleling
options available;
* High base tank capacity: standard skid
offers 470L capacity/containment skidwhich offers 980L capacity (available
as optional on stationary application,
standard on rental). The enclosed set also
features two point lifting - lowered for
easier access, while the compact product
allows 6 units to be fitted in a shipping
container (represents twice as many units
as could previously be fitted into a 40 ft
container). The unit also offer control
panel viewing with a lockable access door.
Rental unit benefits include a noise
compliant enclosure (EC-2000-14), a heavy
duty base frame, a 25-hours fuel tank
and containment capability and a spark
arrestor feature integrated within the
silencer to enable unit to be used in
sensitive locations where sparks would
represent a threat to safety e.g. in oil
drilling/refining locations.
Finally, there is a panel of added
features and options to increase mobility,
access and serviceability.
What more could one ask for?
The QSB7 enclosed gen-set is designed for areas where space is tight,
www.cumminspower.comInternet linkInternet link
IPA
I N D E P E N D E N T P O W E R A S I A • J U N E 2 0 0 9
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I N D E P E N D E N T P O W E R A S I A • J U N E 2 0 0 913
STEAM & TRIGENERATION
Halfway between the centre of Tokyo
and Narita Airport is Makuhari New
City, the centre of Japan’s latest
and blodest trigeneration experiment.
The city's Makuhari District Heating and
Cooling Centre (MDHCC) owned and
operated by EnergyAdvance is
contributing positively to the city which isenergy-rich and environmentally-friendly.
Heat for the district heating and district
cooling system is supplied to the 61.6
hectares of the international business
area of the city.
Two years ago the MDHCC brought in a
new high-efficiency gas engine tri-genera-
tion plant . The results have been
significant in the high energy savings and
reduction of CO2 emissions.
Since the installation of the new system,
MDHCC has raised COP by 0.5 points and
has achieved a 24% reduction of fuelconsumption and cut CO2 emissions by
24,000t/a.
This saving of energy and reduction of
CO2 emissions results from the best mix
of optimum layout and design of high
efficiency equipment such as gas engines
which generate power using clean natural
gas as fuel and optimum operational
technology.
Two high-efficiency Wärtsilä engines
with a power generation efficiency of
45.6% have been introduced for the first
time into Japan. Electrical power
produced by the gas engines runs theelectric turbochiller to produce chilled
water. The surplus electrical power is
used to power the plant and is also sold
to generate cost benefits.
The Wärtsilä gas engines not only
produce high levels of efficiency but they
also provide low costs of operation as
natural gas costs less than fuel oil and the
consumption of lubricating oil is at a mini-
mum level.
A heat recovery system uses the gas
engine's waste heat to produce steam to
power the engine's waste heat boilers toproduce large amounts of steam which
drives absorption chillers that produce
chilled water. Additionally, no steam is
Steam operations in Japan
Clever utilisation of steam is at the heart of the Makuhari District Heating and Cooling
Centre located just outside Tokyo. Many consider it the perfect model of trigeneration.
wasted as it is actively used as a heat
source in all kinds of situations at the
operator's facilities.
The beneficial aspectsSteam created by the furnace flue boiler
becomes the heat source for customer's
heating and is also used as a heat source
for the steam absorption chiller.
Water tube boiler is operated primarily
to drive the steam turbine turbo chiller.
Heat generated during cooling of the gas
engine is sent to the hot water absorptionchiller to be used as a heat source for the
air conditioning.
In addition, high temperature heat
generated by the gas engine is used to
create steam at the heat recovery boiler,
which is used as the heat source to
produce chilled water for air conditioning
at the steam absorption chiller.
The cooling towers are installed on the
upper portion of the pyramid and serve to
radiate heat generated to the chillers.
The district heating and chilling pipelines
are installed in purpose-built culverts
which run throughout the city
The tri-generation power plant
contributes to the local environment by
significantly reducing CO2 emissions and
preventing air pollution by reducing both
NOx and SOx emissions.
The heating and cooling of buildings is,
in many cases, installed by independent
air conditioning systems. The buildings
must each provide everything from
installation of various heating and cooling
sources to management, operation and
maintenance.
On the other hand, district heating and
cooling generates 'heat' such as chilled
water and steam collectively at a single
energy plant.This is a centralised system that supplies
this through pipes to multiple buildings
located within a fixed area. By entrusting
such matters to energy professionals, cus-
tomers are able to use 'heat' that is safe,
secure and environmentally-friendly.
A spokesman for the MDHCC told IPA:
“The concept of tri-generation is now a
proven, cost effective alternative for a
continuous supply of electricity, heating
and cooling needed all year round.”
www.wartsila.com
Internet linkInternet link
IPA
Face of the future? Makuhari District Heating and Cooling Centre (MDHCC), Tokyo.[Inset] A Wärtsilä engine at the heart of the system.
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14
Korea's latest and largest coal-fired,
eco-friendly, high-efficiency power
facility - officially titled the
Yonghung Thermal Power Plant Units 3
and 4 - has been operating at optimal
levels recently. This is all thanks to the
new core facilities and boiler equipment.
Run by Korea South East Power, the unitsare now part of an 870MW-class coal-fired
power plantwhich uses ultra super critical
technology. Moreover, the facility is an
eco-friendly power plant armed with
state-of-the-art, high- efficiency environ-
mental facilities (including desulfurisa-
tion, DeSOx & DeNOx System, and electri-
cal dust collectors).
A company spokesman told IPA: “The
completion of the Yonghung Thermal
Power Plant Units 1 and 2 has contributed
to easing the imbalance between power
supply and demand in the Seoulmetropolitan region, and has helped
stabilise the nation's electricity supply
network. Generators 3 and 4 at the plant
make a significant contribution to
stabilising the power supply during the
peak power demand season in summer.”
Power outputThe Yonghung Thermal Power Plant Units
3 and 4 generate 13.6 billion kWh of elec-
tricity per year, enough to supply 4 million
households. In 2004 Doosan an initial con-
tract for the supply of boilers for the sitein an international bid hosted by Korea
South-East Power in 2004, beating out
Japanese rivals.
Hard on the heels of this successful proj-
ect, Doosna was recently contracted to
supply equipment worth 100 billion won
(£50m) for a project involving the supply
of Korea's largest 340MW- class Fluidised-
Bed Boiler for Yeosu Thermal Power Plant
No. 2 operated by Korea South East
Power.
Doosan President & CEO Geewon Park
commented: "The contract involved thesupply of a 340 MW-class Circulating
Fluidised-Bed Boiler and supplementary
facilities. Unlike a Pulverized Coal Boiler,
which is used in most conventional power
plants, the Circulating Fluidised-Bed
Boiler is an eco-friendly boiler product
which significantly reduces the emission
of pollutants such as nitrogen oxide and
sulphur oxide. Another advantage is that
it can use low-grade coal as fuel, effec-
tively cutting fuel costs.”
Cutting fuel costsWith a Circulating Fluidised-Bed Boiler
at Yeosu replacing the use of heavy oil,
the plant will not only cut down fuel cost
significantly, but also reduce pollutant
emissions. Hence the utility facilities,
once revamped, will transform into an
economical, eco-friendly power plant.
Under the contract, Doosan plans to
design and produce the Circulating
Fluidised- Bed Boiler and supplementary
equipment at its Changwon Plant, anddeliver them by December 2011. Doosan
has also signed a licensing agreement with
Foster Wheeler, a global market leader in
Circulating Fluidised-Bed Boiler
technology, in 2006.
Executive Vice President Dongsoo Suh
said, "With the acquisition of the new
project, Doosan has set a precedent in
the supply of a 340 MW-class Circulating
Fluidised-Bed boiler, the largest scale of
its kind in Korea and among the largest in
the world."
He added: "As the use of low-grade coal
is steadily increasing, Doosan willcontinue to win more orders for
Circulating Fluidised- Bed Boilers not only
in Korea but also in overseas markets in
the future." Doosan also won projects for
the construction of coal-powered thermal
power plants adopting Circulating
Fluidised-Bed Boilers in Thailand and the
Philippines in 2007.
On June 14th, 2009, Doosan Heavy
Industries and Construction signed a
contract worth 74 million euros (US$102
million) with MAPNA Boiler of Iran for the
overall supply of eight heat recovery
steam generators (HRSGs) for four
combined cycle thermal power plants in
the Middle Eastern country. "The project
entails the supply of two HRSGs to each of
the four combined cycle thermal power
plants located in Kahnooj, Iran. Doosan
plans to begin designing the equipment
based on its own technology in June, and
is scheduled to supply them in phases
from April to December of 2010," a
spokesman told IPA.
Doosan Heavy Industries and
Construction secured the top spot in
terms of global market share in 2003
thanks to the acquisition of HRSG orders
worth 240 million euros(US$ 331 million)for the MFPNA combined cycle thermal
power plant, the world's largest single
such project. The company also won
successive orders in the Middle East in
2007 and 2008.
Dong Kyu Lee, head of the HRSG BU at
Doosan Heavy Industries and Construction,
told IPA: "Doosan was able to win the
project thanks to the strong engineering
capacity we have demonstrated during
the execution of our other projects in
Iran.” IPA
I N D E P E N D E N T P O W E R A S I A • J U N E 2 0 0 9
BOILERS
Boilers - a power plant’s heart
Fluidised -bed boiler installation.
www.doosanheavy.com
Internet linkInternet link
Korea South East Power runs an eco-friendly power plant armed with state-of-the-art,high- efficiency environmental facilities - including a DeSOx & DeNOx System, and electrical dust collectors- but a new fluidised bed boiler is key to the operation.
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16
SWITCHGEAR
Over a month ago AREVA's
Transmission and Distribution
division won an order worth over
€80 million from KEPCO, the South Korean
utility, to supply the converter stations for
a 400MW High Voltage Direct Current
(HVDC) bipole scheme linking South
Korea's Jeju Island with the mainland.The converter stations will transform
alternating current into direct current,
connecting the island to the mainland.
AREVA will provide the overall system
design, network studies and detailed
engineering solution for the HVDC
scheme. This will work in conjunction
with the existing 300 MW HVDC bipole link
installed by AREVA in 1997. The new HVDC
scheme will be operational in 2012.
"Through this contract, AREVA reinforces
its HVDC systems expertise and its com-
mitment to working closely withcustomers to develop cost-effective solu-
tions for all their energy needs," Michel
Augonnet, Executive Vice-President for
AREVA's Transmission and Distribution
Systems Business Unit told IPA.
Switchgear from SiemensSiemens Energy is constructing a high
voltage gas-insulated transmission line
(GIL) for Xiluodu China's second largest
hydropower plant "Xiluodu", currently
under construction in the southwest of
the country on the Jinsha Jiang river.
The total tube length for this line is12.5 kilometers. The project involves
seven three-phase systems, each with a
length of approximately 600 metres.
For Siemens, this is the most compre-
hensive GIL installation to date. The gas-
insulated transmission lines provide the
vertical connection between the gas-
insulated high voltage switchgear (GIS) in
the power plant cavern at the foot of the
dam and the overhead line at the edge of
the dam wall.
The gas-insulated high voltage
transmission line is designed for a power
capacity of 3900 megavolt ampere (MVA)
at a voltage of 550 Kilovolt (kV) and a
rated current of 4500 ampere (A). The
Switchgear for Asia The market for gas-insulated high-voltage switchgear has never been more buoyant
when you consider three recent contracts involving India, Korea and China, reports IPA.
order, which was placed by China Three
Gorges Project Corporation, Yichang, has
a value of about €30 million.
Commissioning of the GIL link is projected
for June 2013.
In a hydropower plant such as the one at
the Xiluodu dam, which has a rating of
12,600 megawatts (MW), large amounts of energy need to be transferred from the
foot of the dam to the overhead power
transmission line at the upper end of the
dam wall.
Gas-insulated transmission lines are
particularly well-suited for this purpose
thanks to their high load capacity.
Using a GIL instead of a high-voltage
cable has the added advantage of its
special design which eliminates any risk of
fire. Transmission losses from a GIL line
are also lower than with conventional
high-voltage cables or overhead lines,
says the company.
The virtually maintenance-free design
enables a long service life because the
gas-type insulation system effectively
does not age. Moreover, the GIL tubes are
welded over their entire length.
This not only increases operational
reliability but also gives the GIL a certain
flexibility, so it can adapt to any changes
in the tunnel wall that occur over time.
"With our GIL technology, high power out-
puts can be transmitted very efficiently
even in the very confined spaces that are
common, for example, in this hydropowerstation. With this project, we are helping
to build sustainable energy systems in
China with our solutions," Udo Niehage,
CEO of the Power Transmission Division in
the Siemens Energy Sector told IPA.
Last year, as part of the Jinping I dam
project in China's Sichuan province,
Siemens was awarded the order to
construct a similar GIL link with a total
tube length of 3.2km
Switchgear plants open in India Siemens Energy officially opened a
production faculty for gas-insulated
switchgear (GIS) in Aurangabad, India on
June 5th, 2009, at a total investment cost
of approximately €4 million. Aurangabad
now becomes the centre of manufacture
for 100 series 8DN8 2 switchgear panels
with a rated voltage of up to 145 kilovolts
(kV).
By the year 2013, it is planned to
increase annual production to
approximately 300 switchgear panels and
to expand manufacturing to include
switchgear with a rated voltage of 245 kV.The gas-insulated series 8DN8 2
switchgear - with a rated voltage range up
to 145 kV and a rated operating current of
up to 3150 - will be produced in a facility
covering a surface area of approximately
4200 square metres.
This type of switchgear is among the
most compact in this voltage range. The
design basis for annual production
capacity is 200 switchgear panels in
single-shift operation and 400 panels
in two-shift operation.
This year Siemens provided theswitchgear for the GIL project in
Xiluoda in China.
IPA
I N D E P E N D E N T P O W E R A S I A • J U N E 2 0 0 9
www.siemens.com/energy
www.areva.com
Internet linksInternet links
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17
TURNKEY
South Korea's economy has been
developing steadily for some time
and as a consequence its demands
for power are increasing at an annual rateof approximately 5 - 6%. In recent years a
series of Combined Cycle Gas Turbine
(CCGT) power plants from have provided
significant amounts of reliable power to
South Korea with their high availability,
high electrical efficiencies, low environ-
mental impacts and excellent safety
records.
The latest in this series of award
winning plants is the 565 MW Bugok II
CCGT Power Plant located in South Korea's
Danjin Province, 100kms south of Seoul.
Siemens Energy officially handed over the
new Bugok II CCGT Power Plant to its
customer, GS Electric Power and Services
Co. Ltd., (GS EPS) Seoul and it has been
in full production for 16 months now.
The plant has an efficiency of 58.6 %
and since it started generating
electricity Bugok II has been operating
more as a base load unit instead of a part
load/middle range unit. The plant also
serves under 'Frequency Control Mode'.
Environmentally, the two SGT6-4000F gas
turbines are considered an improvement
on those installed in a sister plant, Bugok
I, located close by.
In principle they are the same heavy
duty type gas turbines that feature in the
Bugok I plant. However, their difference is
in their improved burner and combustion
system which allows operation with high
fuel gas preheating, combined with higher
mass flow from the improved compressor.
Consequently a much more stable
combustion with higher output, higher
efficiency enabling them to operate at
much lower NOX emissions (between 30
and 20 ppm).
The steam turbines also offer great
advantages in cost reduction. They can be
housed in a smaller type of building than
many other steam turbines. This is
because the SST6-5000 turbine is a typical
solution for combined cycle powerproduction where the HP/IP turbine is in
one common cylinder and the LP turbine
is designed for low bay arrangement with
two halves of the condenser on both sides
of the LP turbine. This compact design
means a smaller size without the high
pedestals for the ST foundation that are
normally required.
The control system of Bugok II features
the new Siemens SPPA-T3000 Power Plant
Control System which links together with
the control system of the Bugok I plant
which uses the former TELEPERM XP DCS
system.
This is the first time ever that both
systems were arranged in a manner that
the common systems for both power
plants can be controlled by both DCS
systems.
This parallel linking of the control
systems provides vastly improved control
capabilities for the operators which
advances the efficiencies of the two
plants.
IPA
I N D E P E N D E N T P O W E R A S I A • J U N E 2 0 0 9
South Korea’s Bugok II project
South Korea’s success with Combined Cycle Gas Turbine (CCGT) power plants is
epitomised by the Bugok II project near Seoul, reports IPA's John Goss.
The 565 MW Bugok II CCGT Power Plant is sited in South Korea's Danjin Province
A SPPA-T3000 Power Plant Control
System links the Bugok plants
www.siemens.com
Internet linkInternet link
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EMISSIONS
According to the recent global
emissions analysis undertaken by
CARMA.org Singapore's power
generation industry was highlighted as one
of the few countries in the world which
had made significant reductions in its
carbon-emission intensity.Between 2000 and 2007, the emissions
were reduced by 30%, making it the best
reduction rate within the ASEAN region.
This reduction was attributable in large
measure, say the experts, to Senoko
Power's earlier Stage 1 Repowering pro-
gramme which occurred in 2008.
Through this Stage 2 Repowering
project, the company has been seeking
emission reduction credits, also known as
Certified Emissions Reductions (CERs),
from the United Nations Framework
Convention on Climate Change (UNFCCC)
Executive Board. One CER is equivalent to
one tonne of carbon-dioxide abated. The
CDM allows companies and countries to
mitigate global warming by implementing
projects that result in measurable and
long-term reductions in greenhouse gas
emissions. Roy Adair, President & CEO of
Senoko Power, tells IPA. "In Singapore's
competitive electricity market Senoko has
won many awards, including the SGP
(Singapore Green Plan) 2012 award and
Asian Power's Environmental Power Plant
of the Year (twice) while still competingeffectively in the Singapore Electricity
Market."
The new plants are scheduled for full
commercial operation by the end of 2011.
Just under a year ago Senoko Power
signed a S$750 million Stage 2 repowering
programme to convert its three 30-year-
old Stage 2 oil-fired 250MW steam plants
into two technologically modern and
environmentally-friendly gas-fired 430MW
combined cycle plants (CCPs).
The company has selected a consortium
comprising Mitsubishi Corporation,
Mitsubishi Heavy Industries and Hitachi
Asia as the contractors for the engineer-
ing, procurement and construction of the
new plants. Mitsubishi's latest gas turbines
will be used in this project. Experts say
their efficiency is at least 2 % higher than
the company’s existing CCPs,
representing a low-cost base to provide
competitively-priced electricity to
consumers.
C02 testing of emissions at theGeorgia Institute of Technology, USA
www.senokopower.com/power
Internet linkInternet link
IPA
Emissions impossible
Senoko Power's major repowering programme which have cut back on emissions is a
reflection of Singapore's desire to be eco-friendly across the board, reports IPA.
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